Method of manufacturing a component and thermal management process

ABSTRACT

A method of manufacturing a component and a method of thermal management are provided. The methods include forming at least one portion of the component, printing a cooling member of the component and attaching the at least one portion to the cooling member of the component. The cooling member includes at least one cooling feature. The at least one cooling feature includes at least one cooling channel adjacent to a surface of the component, wherein printing allows for near-net shape geometry of the cooling member with the at least one cooling channel being located within a range of about 127 (0.005 inches) to about 762 micrometers (0.030 inches) from the surface of the component. The method of thermal management also includes transporting a fluid through at least one fluid pathway defined by the at least one cooling channel within the component to cool the component.

FIELD OF THE INVENTION

The present invention is directed to processes of manufacturing andthermal management processes using the manufactured component. Morespecifically, the present invention is directed to manufacturingprocesses for forming components that include cooling features formedtherein.

BACKGROUND OF THE INVENTION

Turbine systems are continuously being modified to increase efficiencyand decrease cost. One method for increasing the efficiency of a turbinesystem includes increasing the operating temperature of the turbinesystem. To increase the temperature, the turbine system must beconstructed of materials able to withstand elevated temperatures duringcontinued use.

In addition to modifying component materials and coatings, one commonmethod of increasing temperature capability of a turbine componentincludes the use of cooling channels. The cooling channels are oftenincorporated into metals and alloys used in high temperature regions ofgas turbines. Manufacturing cooling channels in components can bedifficult and time-consuming. One technique includes casting thechannels in the components using complex molds. The complex molds areoften difficult to position relative to the component surface near thehot gas path where cooling is required. Another technique includesmachining the channels into components after casting, which thenrequires closing the open channels off at the surface of the componentby welding or brazing insert and impingement plates to the surface. Thefinal component is then coated using thermal spraying. Closing thecooling channels can often inadvertently fill the cooling channelsblocking the flow of cooling fluids, such as air from a compressorsection of a gas turbine.

Selective laser melting (or three-dimensional printing) is a relativelyinexpensive process capable of manufacturing difficult to fabricatecomponents. However, components printed by selective laser melting donot have the same temperature capability as cast high temperaturesuperalloy materials. Thus, use in high temperature environments hasbeen perceived as ill-advised.

A method of forming a component and a thermal management process that donot suffer from one or more of the above drawbacks would be desirable inthe art.

BRIEF DESCRIPTION OF THE INVENTION

According to an exemplary embodiment of the present disclosure, a methodof forming a component is provided. The method includes forming at leastone portion of the component, printing a cooling member of thecomponent, and attaching the at least one portion to the cooling memberof the component. The cooling member includes at least one coolingfeature. The at least one cooling feature includes a cooling channeladjacent to a surface of the component, wherein printing allows fornear-net shape geometry of the cooling member with the at least onecooling channel being located within a range of about 127 micrometers(0.005 inches) to about 762 micrometers (0.030 inches) from the surfaceof the component.

According to another exemplary embodiment of the present disclosure, amethod of thermal management of a component is provided. The methodincludes forming at least one portion of the component, printing acooling member of the component, attaching the at least one portion tothe cooling member of the component, and transporting a fluid through atleast one fluid pathway defined by the at least one cooling channelwithin the component to cool the component. The cooling member includesat least one cooling feature. The at least one cooling feature includesat least one cooling channel adjacent to a surface of the component.Printing allows for near-net shape geometry of the cooling member withthe at least one cooling channel being located within a range of about127 micrometers (0.005 inches) to about 762 micrometers (0.030 inches)from the surface of the component. The cooling channel defines a fluidpathway through which the fluid is transported.

Other features and advantages of the present invention will be apparentfrom the following more detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings whichillustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a component including a plurality ofcooling channels formed therein, according to an embodiment of thedisclosure.

FIG. 2 is a exploded perspective view of a cooling member of a componentincluding cooling features.

FIG. 3 is a perspective view of a cooling member of a componentincluding cooling features formed therein, according to an embodiment ofthe disclosure.

FIG. 4 is a cross-sectional view along line 4-4 of FIG. 3 of thecomponent, illustrating a cooling channel formed in the component,according to an embodiment of the disclosure.

FIG. 4 is a cross-sectional view along line 4-4 of FIG. 2 of thecomponent, illustrating at least one cooling channel including supplyand exit passages, according to an embodiment of the disclosure.

FIG. 5 is a cross-sectional view along line 5-5 of FIG. 3 of thecomponent, illustrating cooling features formed in the component,according to an embodiment of the disclosure.

FIG. 6 is a cross-sectional view along line 6-6 of FIG. 5 of a coolingchannel formed in the component illustrating features that disruptlaminar flow of a fluid, according to an embodiment of the disclosure.

Wherever possible, the same reference numbers will be used throughoutthe drawings to represent the same parts.

DETAILED DESCRIPTION OF THE INVENTION

Provided is a manufacturing process and a thermal management processusing the manufactured component. Embodiments of the present disclosure,in comparison to processes and articles that do not include one or moreof the features disclosed herein, provide additional cooling andheating, permit cooling in new regions, permit cooling with newmaterials, permit cooler and/or hotter streams to be directed from flowwithin turbine components, permit the useful life of turbine componentsto be extended, permit turbine systems using embodiments of the turbinecomponents to be more efficient, permit turbine components to bemanufactured more easily, permit manufacturing of cooling features thatpreviously could not be made, permit manufacturing of components thatotherwise cannot be made using traditional manufacturing processes,permit hybrid material construction of turbine components or acombination thereof.

One or more specific embodiments of the present invention will bedescribed below. In an effort to provide a concise description of theseembodiments, all features of an actual implementation may not bedescribed in the specification. It should be appreciated that in thedevelopment of any such actual implementation, as in any engineering ordesign project, numerous implementation-specific decisions must be madeto achieve the developers' specific goals, such as compliance withsystem-related and business-related constraints, which may vary from oneimplementation to another. Moreover, it should be appreciated that sucha development effort might be complex and time consuming, but wouldnevertheless be a routine undertaking of design, fabrication, andmanufacture for those of ordinary skill having the benefit of thisdisclosure.

When introducing elements of various embodiments of the presentinvention, the articles “a,” “an,” “the,” and “said” are intended tomean that there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.

The term “printing” refers to a three-dimensional printing process.Examples of three-dimensional printing processes include, but are notlimited to, the processes known to those of ordinary skill in the art,such as Direct Metal Laser Melting (“DMLM”), Direct Metal LaserSintering (“DMLS”), Selective Laser Sintering (“SLS”), Selective LaserMelting (“SLM”), and Electron Beam Melting (“EBM”). As used herein, theterm “three-dimensional printing process” refers to the processesdescribed above as well as other suitable current or future processesthat include the build-up of materials layer by layer.

Referring to FIG. 1, in one embodiment, the component 100 may be astatic component, rotating component or combustion hardware in a turbinesystem. Examples of static components include, but are not limited to,nozzles, vanes, shrouds, near flow path seals, transition pieces, andcombinations thereof. Component 100 includes at least one portion 110and a cooling member 120. Cooling member 120 is attached to at least oneportion 110 by any suitable joining technique, such as, but not limitedto, brazing, welding or mechanical means. For example, in FIG. 1,component 100, a nozzle, includes cooling member 120, an airfoil,attached to a first end portion 114 and a second end portion 112.

To manufacture component 100, at least one portion 110 is formed.Suitable methods for forming at least one portion 110 include casting orprinting. In one embodiment, at least one portion 110 is formed usingtraditional manufacturing methods, such as, but not limited to casting.At least one portion 110 may be cast using molds to form the desiredshape using desired materials to provide desired strength and thermalcharacteristics.

Printing cooling member 120 or at least one portion 110 may includeusing three-dimensional printing to form at least one cooling feature122 (see FIGS. 2 and 5). The at least one cooling feature 122 includescooling channels 130 and cooling cavities 490 and 590. The at least onecooling channel 130 is adjacent to the surface 322 of component 100. Inan alternative embodiment, as shown in FIG. 2, a segment of coolingmember 120 or portion 110 may be printed with at least one coolingchannel 130, then the printed segment of cooling member 120 or portion110 including at least one cooling channel 130 is attached to othersegments of cooling member 120 or portion 110, without cooling channels.The other segment of cooling member 120 or portion 110 may be formedusing methods such as, but not limited to, casting, forging, orprinting. The three-dimensional printing includes distributing anatomized powder onto a substrate plate (not shown) using a coatingmechanism (not shown). The substrate plate is positioned within achamber (not shown) having a controlled atmosphere, for example, aninert gas, such as argon, nitrogen, other suitable inert gases, or acombination thereof. The atomized powder is melted, for example, byelectron beam melting, laser melting, or other melting from other energysources, to form a portion or layer of a three-dimensional product, suchas, a segment of cooling member 120 or at least one portion 110 of acomponent 100. The process is repeated to form the three-dimensionalproduct, such as cooling member 120 or portion 110.

Three-dimensional printing may use atomized powders that arethermoplastic, metal, metallic, ceramic, other suitable materials, or acombination thereof. Suitable materials for the atomized powder include,but are not limited to, stainless steel, tool steel, cobalt chrome,titanium, aluminum, alloys thereof, nickel based superalloys, orcombinations thereof. In one embodiment, the material for the atomizedpowder corresponds with material for an alloy suitable for the hot-gaspath of a turbine system. The material for cooling member 120 may be thesame or different than material chosen for portion 110. At least oneportion 110 may be selected from a first material and cooling member 120may be selected from a second material. In one embodiment, the firstmaterial may be different than the second material. Alternatively, thefirst material may be the same as the second material. Suitable examplesof first material for at least one portion 110, include, but are notlimited to, nickel, iron, cobalt, chromium, molybdenum, aluminum,titanium, gold, silver, stainless steel, alloys thereof, nickel basedsuperalloys, cobalt superalloys, or combinations thereof. Suitableexamples of second material for cooling member 120, include, but are notlimited to, nickel, iron, cobalt, chromium, molybdenum, aluminum,titanium, gold, silver, stainless steel, alloys thereof, nickel basedsuperalloys, cobalt superalloys, or combinations thereof. Suitableexamples of commercially available materials, include, but are notlimited to, Co—Cr (70Co, 27Cr, 3Mo), Stainless Steel 316, INCONEL® alloy625 and INCONEL® alloy 718, INCONEL® alloy 738 (INCONEL® being availablefrom Special Metals Corporation, Princeton, Ky.), GTD-222® (a trademarkof General Electric Company), Haynes® 282® alloy (available from HaynesInternational, Kokomo, Ind.), UDIMET® alloy 500 (being available fromSpecial Metals Corporation, Princeton, Ky.). In one embodiment, materialfor cooling member 120 may be chosen so as to have a higher thermalconductivity than the material from which at least one portion 110 isformed thereby enabling increased efficiency and requiring less fluid tobe used to alter the temperature of surface 322 of component 100.

One example of a three-dimensional printing process is selective lasermelting which uses a predetermined design file or two-dimensional slicesof a three-dimensional file, for example, from a computer-aided designprogram. The thickness of the two-dimensional slices determines theresolution of the selective laser melting. For example, when thetwo-dimensional slices are 20 micrometers thick, the resolution will begreater than when the two-dimensional slices are 100 micrometers thickfor the printing of a predetermined component, such as, the coolingmember 120. In one embodiment, cooling member 120 or at least oneportion 110 formed from the printing is near-net-shape and includes aplurality of cooling features 122 such as at least one cooling cavity490, 590 and a plurality of cooling channels 130 formed therein. Asshown in FIG. 2, cooling member 120 may be an airfoil, havingnear-net-shape and a plurality of cooling features 122 such as coolingcavities 490, 590 and cooling channels 130 formed therein. In oneembodiment, cooling member 120 may be printed as a single piece (seeFIG. 1). In an alternative embodiment, as shown in FIGS. 2 and 3,cooling member 120 may be formed as a first segment 260 including aplurality of cooling channels 130 and at least one cooling cavity 490and at least one second segment 280 optionally including a plurality ofcooling cavities 590. As shown in FIGS. 2 and 3, the at least onecooling cavity 490 of the first segment 260 may be aligned with the atleast one cooling cavity 590 of the second cavity. The first segment 260may be joined to the at least one second segment 280 using any suitablejoining technique, shown by dashed lines 270 (see FIG. 3). Printedcooling member 120 includes a first end 222 and a second end 224. Firstend 222 or second end 224 may be attached to portion 110 using anysuitable joining process, such as, but not limited to, brazing, weldingor mechanical attachment means. As shown in FIG. 1, first end 222 ofcooling member 120 is attached to first end portion 114 and second end224 of cooling member 120 is attached to second end portion 112 bywelding or brazing, illustrated by a joint 140. Suitable examples ofattaching include, but are not limited to, arc welding, beam welding,brazing, transient liquid phase (TLP) bonding, and diffusion bonding.

In one embodiment, as shown in FIG. 1, cooling member 120 is a singleprinted piece including cooling channels 130, cooling cavities 490 andfirst openings 150 or supply passages and second openings 160 or exitpassages formed therein. In an alternative embodiment, as shown in FIGS.2 and 3, cooling member 120 is formed in steps. In one step, a firstsegment 260 including a plurality of cooling features 122 includingcooling channels 130 and/or cooling cavities 490 and/or first and secondopenings 150 and 160 are printed. In another step, at least one secondsegment 280 is formed using three-dimensional printing or traditionalcasting techniques. As discussed above, first segment 260 may be formedusing a first material and at least one second segment 280 may be formedusing a second material. In one embodiment, first and second materialsare the same. In an alternative embodiment, first and second materialsare different. After first segment 260 and at least one second segment280 are formed, cooling member 120 is built by joining first segment 260and at least one second segment 280 along joint lines 270 (see FIG. 3).Any suitable joining method may be used to join first segment 260 and atleast one second segment 280, such as, but not limited to, arc welding,beam welding, brazing, transient liquid phase (TLP) bonding, anddiffusion bonding.

As shown in FIG. 4, first openings 150 of supply passages from coolingcavity 490 to cooling channel 130 and second openings 160 or exitpassages for coolant to leave channel 130 may also be printed intocooling member 120 or first segment 260 of cooling member 120. Firstopenings 150 or inlets may be attached to cooling channel cavities 490running throughout the length of component 100. First openings 150 andsecond openings 160 are interconnected by cooling channels 130. In oneembodiment, second openings 160 may be cylindrical holes but could alsobe shaped holes to enable coolant exiting the cooling channel 130 toprovide film coverage to the downstream portion of the component. Secondopenings 160 or exit passages may also be trenches where coolant fromone or more cooling channels 130 enters to spread along the trench andthen exit the trench as film (see FIG. 1).

Referring to FIG. 5, using three-dimensional printing allows the atleast one cooling channel 130 to be located at a distance 350 within arange of about 127 micrometers (0.005 inches) to about 762 micrometers(0.030 inches) from surface 322 of cooling member 120 of component 100.Alternatively, three-dimensional printing allows the at least onecooling channel 130 to be located at a distance 350 of at least lessthan about 508 micrometers (0.020 inches) from the surface 322 ofcooling member 120 of component 100 (see FIG. 5). Distance 350 betweencooling channel 130 and surface 322 of component 100 may be up to atleast less than or as little as about 127 micrometers (0.005 inches).Distance 350 between cooling channel 130 and surface 322 of component100 may be constant throughout cooling channel 130 length in component100. In an alternative embodiment, distance 350 may be varied throughoutlength of cooling channel 130 in component 100 (see FIG. 4). Distance350 may be from about 127 micrometers (0.005 inches) to about 1524micrometers (0.060 inches), or alternatively about 254 micrometers(0.010 inches) to about 1270 micrometers, or alternatively about 254micrometers (0.010 inches) to about 1016 micrometers, or alternativelyabout 254 micrometers (0.010 inches) to about 508 micrometers (0.020inches), or alternatively less than about 508 micrometers (0.020inches), or alternatively about 254 micrometers (0.010 inches) oralternatively about 127 micrometers (0.005 inches). In comparison,typical casting methods used to form a component with cooling channelswill have cooling channels located at about 2540 micrometers (0.100inches) from surface.

Using three-dimensional printing to form at least one cooling channel130 in cooling member 120 or at least one portion 110 reducesmanufacturing steps and saves time and resources because coolingchannels do not need to be drilled into the surface of component.Printing cooling member 120 or at least one portion 110 with coolingchannels 130 formed therein also reduces manufacturing steps and timeand resources because open cooling channels do not need to be closedusing insert plates. The three-dimensional printing processes alsoallows the geometry (length, width, height, and depth) of the coolingchannels 130 and at least one fluid pathway 360 therein to be variedalong the length of cooling channel 130 within cooling member 120. Forexample, cooling channel 130 may constrict or narrow in some areas orwiden in other areas to match the cooling or heating local demands ofcomponent 100. Cooling channel 130 dimensions may be changed asnecessary and the dimensions do not need to be constant from one end toanother. In one embodiment, cooling channel 130 may be a semi-circlehaving a width and depth of about 254 micrometers (0.010 inches) toabout 2540 micrometers (0,100 inches) or alternatively about 762micrometers (0.030 inches) to about 1524 micrometers (0.060 inches).

In one embodiment, prior to joining cooling member 120 to at least oneportion 110, an optional step of hot isostatic pressing (HIP) and/orsolution heat-treating is performed to strengthen the printed coolingmember 120 or at least one portion 110. During HIP operation, internaldefects such as porosity and microfissures are closed or healed due tothe temperature and applied pressure. During solution heat treatment,all deleterious precipitates are put into solution in the materialmatrix thereby providing the best properties. These heat treatmentschange the grain structure through formation of new grains ultimatelystrengthening the printed cooling member 120.

As shown in FIG. 4, surface 322 may be coated with a protective coating340. Protective coating 340 may include any number of layers, such as,but not limited to a bond coating 342 and thermal barrier coating 344applied to bond coating 342. Protective coating 340 may be applied priorto joining cooling member 120 to at least one portion 110. Protectivecoating 340 may be applied after cooling member 120 is jointed to atleast one portion 110 by welding, brazing or other suitable mechanicaljoining means.

Transporting a fluid through at least one fluid pathway 360 defined byat least one cooling channel 130 within the component alters, cools, orheats surface 322 of component 100. The changes in geometry may bedesigned so as to maximize or minimize the alteration of temperature atany particular location along the length of at least one cooling channel130 in component 100. The changes in geometry may enable highly specificmanipulation of the thermal characteristics of surface 322 by at leastone cooling channel 130. The geometry changes may enable themodification of thermal management properties of a component design withminimized cost and time compared to methods and articles that do notinclude one or more of the features disclosed herein.

Referring to FIG. 6, in one embodiment, at least one cooling channel 130may include at least one feature to disrupt laminar flow of a fluidthrough the at least one fluid pathway 360. The at least one feature todisrupt laminar flow may include turbulators 406, which mix the fluid inthe at least one fluid pathway 360 from the middle to the sides and fromthe sides to the middle, making the at least one fluid pathway 360effectively longer. Turbulators 406 may also increase the surface areaof at least one cooling channel 130, which increases heat transfer fromor to the fluid flowing through the at least one fluid pathway 360 to orfrom the substrate 322. Suitable examples of turbulators 406 include,but are not limited to, fin 410 and bumps 412. Turbulators 406 may be ofany suitable shape or size, and may be included on the at least oneinner surface of cooling channel 130 in any suitable arrangement orspacing to achieve the desired effect. Turbulators 406 may be formedwithin at least one cooling channel 130 using a three-dimensionalprinting process, resulting in a single homogeneous piece.

Also provided is a method of thermal management. The method includesforming at least one portion 110 of component 100 (see FIG. 1). Themethod includes printing a cooling member 120 (see FIG. 1) or firstsegment 260 and at least one second segment 280 and building coolingmember 120 of component 100 (see FIGS. 2 and 3). The method includesattaching the at least one portion 110 to cooling member 120 ofcomponent 100 (see FIG. 1). The method includes transporting a fluidthrough the at least one fluid pathway 360 defined by the at least onecooling channel 130 within component 100 to cool component 100 (seeFIGS. 4 and 6).

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

What is claimed is:
 1. A method of manufacturing a component comprising:forming at least one portion of the component; printing a cooling memberof the component, the cooling member including at least one coolingfeature, the at least one cooling feature including at least one coolingchannel adjacent to a surface of the component, wherein printing allowsfor near-net shape geometry of the cooling member with the at least onecooling channel being located within a range of about 127 (0.005 inches)to about 762 micrometers (0.030 inches) from the surface of thecomponent; and attaching the at least one portion to the cooling memberof the component.
 2. The method of claim 1, wherein the at least onecooling feature further includes at least one cooling cavity adjacent tothe at least one cooling channel.
 3. The method of claim 2, wherein thestep of printing further includes creating a first opening in the atleast one cooling channel, the first opening joining the at least onecooling cavity to the at least one cooling channel.
 4. The method ofclaim 3, wherein the step of printing further includes creating a secondopening in the at least one cooling channel, the second opening being inthe surface of the component.
 5. The method of claim 2, wherein the atleast one portion of the component further includes at least one coolingcavity.
 6. The method of claim 5, wherein the at least one coolingcavity of the at least one portion aligns with the at least one coolingcavity of the cooling member.
 7. The method of claim 1, wherein the stepof forming includes casting or three-dimensional printing of the atleast one portion.
 8. The method of claim 1, wherein the step ofprinting uses a three-dimensional printing process.
 9. The method ofclaim 1, wherein the step of attaching includes welding, brazingtransient liquid phase (TLP) bonding, diffusion bonding, mechanicalattachment, or combinations thereof.
 10. The method of claim 1, whereinthe at least one portion is selected from a first material and thecooling member is selected from a second material.
 11. The method ofclaim 10, wherein the first material is the same as the second material.12. The method of claim 10, wherein the first material is different thanthe second material.
 13. The method of claim 10, wherein the firstmaterial is selected from nickel, iron, cobalt, chromium, molybdenum,aluminum, titanium, stainless steel, nickel based superalloys, cobaltsuper alloys or combinations thereof.
 14. The method of claim 10,wherein the second material is selected from nickel, iron, cobalt,chromium, molybdenum, aluminum, titanium, stainless steel, nickel basedsuperalloys, cobalt super alloys or combinations thereof.
 15. The methodof claim 1, wherein the at least one cooling channel is located at leastless than about 508 micrometers (0.020 inches) away from the surface ofthe component.
 16. The method of claim 1, wherein the at least onecooling channel is located at least less than about 254 micrometers(0.010 inches) away from the surface of the component.
 17. The method ofclaim 1, wherein the at least one cooling channel has a varying geometrythroughout the cooling member.
 18. The method of claim 1, furthercomprising applying at least one protective coating after the step ofattaching.
 19. A method of thermal management of a component comprising:forming at least one portion of the component; printing a cooling memberof the component, the cooling member including at least one coolingfeature, the at least one cooling feature including at least one coolingchannel adjacent to a surface of the component, wherein printing allowsfor near-net shape geometry of the cooling member with the at least onecooling channel being located within a range of about 127 (0.005 inches)to about 762 micrometers (0.030 inches) from the surface of thecomponent; attaching the at least one portion to the cooling member ofthe component; and transporting a fluid through at least one fluidpathway defined by the at least one cooling channel within the componentto cool the component.
 20. The method of claim 20, wherein the at leastone cooling channel is located at least less than about 508 micrometers(0.020 inches) away from the surface of the component.